Future-Facing Minerals

Carrapateena Mine Underground Crusher 2.0

Client

BHP

Duration

Oct 2022 - Apr 2024

Location

Pernatty, South Australia, Australia

Value

36.4 million

A pivotal upgrade to one of South Australia’s key copper assets – delivered without disruption, setting the groundwork for long-term performance uplift.

Carrapateena Underground Crusher 2.0 marked a pivotal step in unlocking long-term performance at one of South Australia’s most important copper assets. The project introduced new underground crushing and materials handling infrastructure, designed to enable 7Mtpa ore throughput by conveying product directly to surface – reducing diesel haulage and improving safety.

Delivered within a live mine environment, the works were staged through confined tunnels and ventilation-reliant spaces with active haulage and fixed plant operations nearby. Tight access, limited laydown, and concurrent contractor activity demanded rigorous interface control, adaptive scheduling, and round-the-clock coordination. PHE Group was engaged to deliver the full electrical and instrumentation package, drawing on deep site familiarity and a proven record of performance in high-risk environments.

Project Scope

Electrical and instrumentation (E&I) works delivered across five conveyors and four transfer stations.
Installation of 2,693 cables totalling more than 126,000 metres in length, including over 12,165 metres of high voltage cabling.
Design, installation, and connection of seven switchrooms – two preassembled, five constructed and fit out underground.
Installation of over 50,000 metres of catenary support systems and more than 4,750 metres of cable ladder systems.
Reticulation of 11kV power, installation of underground dewatering systems, and a new mobile plant workshop.
Installation of 868 electrical and instrumentation assets, along with nine hydraulic ventilation control doors.

Innovations and Solutions

Integrated in-slab conduits eliminated secondary cable routing risks and improved safety.
Additional boreholes were recommended early to improve cable routing across underground levels.
High voltage cables were re-routed above structural elements to ease installation and future maintenance.
Wi-Fi infrastructure was installed underground to enable mobile-based QA uploads in real time.
Cable usage was tracked through PHE's custom-built digital Drum Register, improving traceability.
Daily access plans and interface maps were developed to coordinate works within a restricted tunnel network.
Equipment and switchrooms were transported in sections and reassembled underground to overcome access limitations.
Construction staging was adapted in real time to navigate mining progress and operational constraints.
Early Contractor Involvement (ECI) enabled PHE to shape scope and sequencing before contract award, supporting constructability and maintaining momentum. Design risks were identified early, allowing for smarter procurement and fewer interface delays.

Outcomes and Benefits

Underground haulage was reduced by 75%, lowering emissions and critical vehicle interaction risk.
Zero lost-time injuries were recorded across more than 238,000 hours worked – demonstrating a deeply embedded safety culture in high-risk environments.
More than $2.25M of out-of-scope procurement was managed in-house, preserving delivery momentum and protecting the project timeline.
Eighteen PHE apprentices contributed over 30,000 hours – helping build future workforce capability while supporting day-to-day delivery.
Several apprentices have since progressed into senior roles – reflecting PHE's long-term investment in skills development and internal progression.
All underground works were delivered without interrupting mine production – ensuring operational continuity and avoiding costly downtime.
Local suppliers in Port Augusta were prioritised – reinforcing PHE's commitment to regional industry and supply chain resilience.
PHE Group’s underground expertise and sequencing discipline maintained schedule certainty – even under confined, interface-restricted conditions.
The project has strengthened PHE Group’s long-standing relationship with BHP and Copper SA – creating a foundation for future collaboration through trusted performance.
Crusher 2.0 supports the long-term viability of low-emission copper operations – reinforcing Carrapateena’s role in Australia’s future-facing resource economy.

LTI-Free Hours

238K+

Underground Haulage Reduction

75%

Training Hours

30K

Project Images